Method for manufacturing mold

ABSTRACT

A method for manufacturing a mold ( 70 ), which comprises a step of forming a layer ( 31 ) of combustible powdery particles ( 32 ) around a wax mold ( 21 ), which is a lost pattern, a step of forming a film ( 51 ) of a ceramic precursor slurry ( 52 ) around the wax mold ( 21 ) having powdery particles ( 32 ) formed thereon, a step of subjecting the resultant product to a heat treatment, to thereby dewax the wax mold ( 21 ), and a step of firing the slurry film ( 51 ), to thereby burn and vanish the powdery particles ( 32 ) in the slurry film ( 51 ) and form a shell ( 71 ). The mold ( 70 ) has the shell ( 71 ) and a porous layer ( 74 ) formed on the surface ( 76 ) of the cavity of the shell. The mold can be suitably used for manufacturing a porous body ( 90 ) having a porous layer ( 94 ) on the surface thereof.

TECHNICAL FIELD

The present invention relates to a method for manufacturing a mold usedfor an investment casting.

BACKGROUND ART

In a carrier of a catalyst, or an artificial bone, an artificial dentalroot (hereinafter, referred to as an implant member) for artificialbiomaterial transplantation, a porous layer having a porous structure isformed on the surface in order to increase a surface area.

As a method for forming a porous layer having a porous structure on asurface, the following two methods have been used, that is, (1) a methodcarrying out a laser beam machining on the surface of a metallic body(or an alloy body), and (2) a method piling up thin sheets made withmetallic materials having many pores while three-dimensionallycontrolling a hole shape in the porous structure, which is described inJapanese Patent Application Laid-Open No. H10-155823.

Incidentally, as for the manufacturing method (1), although the metallicbody (or the alloy body) having a porous structure only on the surface,that is, a rough surface, can be easily obtained, there was the problemthat a porous layer having a three-dimensional porous structure cannotbe obtained. Further, in the case of a metal (or an alloy) having highmelting point, there were problems that a high output laser beam machineand a long processing time were necessary for the laser beam machining.

Further, as for the manufacturing method (2), although a porous layerhaving a three-dimensional porous structure could be formed, there wereproblems that it took the time and effort for controlling the pore shapeand that a long time was necessary for manufacturing.

Thus, it is desired that the above-mentioned porous layer is made by acasting method capable of comparatively easy manufacture. When a porousarticle is manufactured by the casting method, projections formed on aninner surface of a mold constitute pores of a porous article. However,in order to take out a cast body from the mold, the head of eachprojection must be narrower than its base. Therefore, as for the poreshape of the porous article obtained by the casting method, a bottompart of the pore is narrower than an opening part of the hole. As aresult, for example, one like a golf ball having a concave dimple on thesurface could be cast, but there was a problem to make a cast articlehaving a complicated three-dimensional porous structure on the surfaceby casting.

The present invention solves the above-mentioned problems, and theprimary objective is to provide a method for manufacturing a mold,wherein a porous body can be made.

DISCLOSURE OF INVENTION

One embodiment of the present invention is as follows. That is, a layerof combustible powdery particles is formed around a wax mold, which is alost pattern. A film of a ceramic precursor slurry is coated around thewax mold having a layer of powdery particles formed thereon. Then, aresultant product is heated to dewax the wax mold, and thereafter, theslurry film is fired to burn and vanish the powdery particles inside theslurry film, and to form a shell. Thereby, the mold having a porouslayer on the surface of the cavity of the shell can be made, wherein theporous layer has a three-dimensional porous structure.

Another embodiment of the present invention is as follows. That is, alayer of combustible powdery particles is formed on an inner surface ofa female mold for forming a wax mold, which is a lost pattern. A waxmaterial is injected into the female mold, and the wax mold is formedaround which has the layer of the powdery particles. Then, a film of aceramic precursor slurry is coated around the wax mold. Then, afterdewaxing the wax mold by heating, the powdery particles inside of theslurry film is burned and vanished by firing the slurry film, and ashell is formed. Thereby, the mold having a porous layer on the surfaceof the cavity of the shell can be manufactured, wherein the porous layerhas a three-dimensional porous structure.

Another embodiment of the present invention is a mold made by any one ofthe above-described methods for manufacturing the mold, and the mold hasa porous layer on the surface of the cavity of a shell, wherein theporous layer has a three-dimensional porous structure.

In addition, another embodiment of the present invention is a method formanufacturing a cast article by the steps of pouring a molten metal intothe cavity of a mold obtained by any one of the above-described methodsfor manufacturing the mold, cooling the molten metal, and removing theshell. Thereby, it is possible to manufacture a cast article having aporous layer at least on the surface thereof, wherein the porous layerhas a three-dimensional porous structure.

Furthermore, another embodiment of the present invention is a castarticle manufactured by any one of the above-described methods. Thereby,it is possible to manufacture the cast article having a porous layer atleast on the surface thereof, wherein the porous layer has athree-dimensional porous structure, and preferably to manufacture animplant member, a catalyst carrier, a turbine rotor, a turbine blade, orthe like.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a flow chart showing a casting method of a cast articleaccording to one preferred embodiment of the present invention.

FIG. 2 is a perspective schematic view illustrating one example of a waxmold.

FIG. 3 is a perspective schematic view of a wax mold where a layer ofcombustible powdery particles is formed around the wax mold shown inFIG. 2.

FIG. 4 is a cross-sectional view taken along the line 44 shown in FIG.3.

FIG. 5 is a cross-sectional view when a film of ceramic precursor slurryis coated around the wax mold shown in FIG. 4.

FIG. 6 is a cross-sectional view of a mold precursor obtained bydewaxing the wax from the coated wax mold shown in FIG. 5.

FIG. 7 is a cross-sectional view of a mold obtained by a firingtreatment to the mold precursor shown in FIG. 6.

FIG. 8 is a cross-sectional view when a molten metal is poured into themold shown in FIG. 7.

FIG. 9 is a cross-sectional view of a cast article according to onepreferred embodiment of the present invention.

FIG. 10 is a flow chart showing a casting method of a cast articleaccording to another preferred embodiment of the present invention.

FIG. 11 is a cross-sectional schematic view for describing a process Dshown in FIG. 1.

FIG. 12A is a cross-sectional schematic view for describing a process D2shown in FIG. 10.

FIG. 12B is a cross-sectional schematic view when a wax molding body istaken out from a metallic mold in a process C shown in FIG. 10.

FIG. 13 is a cross-sectional observation view of a cast article obtainedin Example 1.

FIG. 14 is a cross-sectional observation view of a cast article obtainedin Example 2.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

The present invention is described more extensively with attacheddrawings.

FIG. 1 illustrates a flow chart of a casting method of a cast articleaccording to one preferred embodiment of the present invention.

As illustrated in FIG. 1, the casting method of the cast articleaccording to the present preferred embodiment uses an investment castingmethod (a lost wax method).

The method comprises steps of first manufacturing a metallic mold (afemale mold) having a cavity with a predetermined shape (Process A),pouring a wax material into the metallic mold by a method such as aninjection molding or the like (Process B), and taking out a wax moldingbody from the metallic mold after hardening the wax material (ProcessC). A wax mold (a male mold) 21, which is a lost pattern as illustratedin FIG. 2, can be obtained using the wax molding body. During theprocesses A to C, two kinds or more of wax molding bodies may be formedif necessary, to thereby obtain the desired wax mold 21 by assemblingthose. The wax mold 21 comprises an ingate, a runner and a sprue, whichare used in the below-described casting although not illustrated in thedrawings. Further, a plurality of wax molds may be integrated into atree shape or a cluster shape. The wax material in this case includesnot only waxes themselves but also whole resins (plastics).

Then, as illustrated in FIG. 3, a layer 31 consisting of manycombustible powdery particles 32 is formed at a desired part around thewax mold 21 (Process D). Preferably, as illustrated in FIG. 4 as a crosssectional diagram which is taken along the line 4-4 in FIG. 3, manypowdery or granular combustible powdery particles 32 are adhered at apart around the mold wax 21, wherein the part is desired to have athree-dimensional porous structure. Thereby, it is possible to obtain awax mold 30 having the layer 31 formed around thereon, wherein the layer31 has a three-dimensional porous structure 33.

At this time, it is possible to obtain the porous structure 33 whosepores are arranged randomly, or the porous structure 33 whose pores arealigned in a predetermined direction, by controlling an arrangement ofeach powdery particle 32 adhered around the wax mold 21. Further, thepore size and shape of the porous structure 33 can be controlled bychanging the size and shape of the powdery particles 32. Furthermore,the thickness of a porous layer 74 of a mold 70 as described below, thatis, the thickness of a porous layer 94 of a cast article 90 can becontrolled by controlling the thickness of the layer 31.

Then, as illustrated in FIG. 5, after a film of a ceramic precursorslurry 52 is adhered around the wax mold 30, the slurry 52 is dried, andthen, a slurry film 51 is coated around the wax mold 30 (Process E). Atthis time, the slurry 52 also enters into a part of the porous structure33 of the layer 31,that is, enters into a void space of the layer 31,and all the powdery particles 32 are covered with the slurry film 51. Asa method for adhering the slurry 52, a dipping method, a sprayingmethod, or a coating method can be used, but the dipping method ispreferable since it has sufficient permeability of the slurry 52 to theinside of the layer 31. Further, the film thickness of the slurry film51 is controlled so as to have a desired thickness by repeatingoperations of adhering and drying of the slurry 52.

The wax mold 30 having the slurry film 51 coated thereon is subjected toa heat and pressure treatment at 4 to 8 atmospheres and at 100 to 180°C., preferably at 140 to 160° C., to thereby dewax the wax mold (ProcessF). Thereby, as illustrated in FIG. 6, the wax material is melted, andthe wax mold 21 is lost to become a cavity 61, to thereby obtain a moldprecursor (a mold preformed body) 60 having the cavity 61 inside theslurry film 51. In this process, each powdery particle 32 inside theslurry film 51 does not vanish but remains, and the shape of eachpowdery particle 32 (the layer 31) is kept.

After dewaxing, the mold precursor 60 is subjected to a firing treatmentat a temperature of 900 to 1,300° C. (Process G), and as illustrated inFIG. 7, the slurry film 51 is fired to be hardened to form a shell 71.In the firing treatment, each combustible powdery particle 32 remainingin the mold precursor 60 is burned and vanished gradually from a sidefacing to the cavity 61 toward the inner side of the mold precursor 60,before forming the shell 71. A portion occupied by each powdery particle32 becomes a fine void space 75 by this burning. A gas g generated whileburning a certain powdery particle 32 reaches to the cavity 61 of themold precursor 60 passing through the adjacent fine void space 75, andthen exhausted to the outside of the mold precursor 60. As for theburning and vanishing temperature of the powdery particles 32, theparticle material is selected so that the temperature is not more thanthe firing temperature of the slurry film 51, preferably lower than thefiring temperature of the slurry film 51 by 90° C. or more, and morepreferably lower than the firing temperature of the slurry film 51 by100° C. or more. As a result, when each powdery particle 32 is burnedand vanished, it is unlikely that the fine void space 75 is damaged bythe generated gas g. Thus, the shape of the fine void space 75 can bekept, and the fine void spaces 75 link each other. Thereby, asillustrated in FIG. 7, it is possible to obtain the mold 70 made ofceramics having a cavity 72 inside the shell 71, wherein the cavity 72is comprised of the cavity 61 having the same shape as the wax mold 21and a group of the fine void space 75 having the same shape as eachpowdery particle 32 (the layer 31). That is, the mold 70 has the porouslayer 74 on the surface 76 of the cavity of the shell 71, wherein theporous layer 74 has a three-dimensional porous structure 73.

Then, as illustrated in FIG. 8, a molten metal 81 is poured into thecavity 72 of the mold 70 to be cast (Process H). At this time, sinceeach fine void space 75 links one another, the molten metal 81 entersinto up to every hole and corner of each fine void space 75. Then, themolten metal 81 is cooled (Process I) and then, the casting iscompleted. Thereby, a cast body 82 is formed in the mold 70. As a methodfor casting the molten metal 81, a pouring casting method, a centrifugalcasting method, a suction casting method (low pressure casting), or thelike can be applicable.

After the casting, the shell 71 is subjected to blast cleaning to removethe shell 71 (Process J). Thereby, as illustrated in FIG. 9, a castarticle 90 as an integrated article having a porous layer 94 at least onthe surface thereof can be obtained, wherein the porous layer 94 has athree-dimensional porous structure 93. As the method of the blastcleaning, any one of a sand blast method, a shot blast method, and awater jet method (spraying of high-pressure water) may be used. Further,as a method for removing the shell 71 other than the blast cleaning, ashakeout method can be used.

In this case, as a matrix of the powdery or granular combustible powderyparticles 32, it is not especially limited if it can be completely (orsubstantially completely) burned and vanished at the temperature of thefiring treatment of 900 to 1,300° C. For example, wood, fiber, carbon(graphite) or the like can be used. Further, as a method for adheringmany powdery particles 32 around the wax mold 21, it is not especiallylimited, and for example, a method for coating an adhesive or a cohesiveagent around the wax mold 21 can be used. At this time, if the adhesiveor the cohesive agent is adhered around the powder particle 32excessively, the fine void space 75 cannot be formed with sufficientaccuracy, so that it is not preferable.

The matrix of the molten metal 81 is not especially limited if it isgenerally used as a metal (or an alloy) for casting. However, as thematrix, an alloy having a relatively high melting point, such as aTi-based alloy, a Co-based alloy, a Ni-based alloy and an Al-basedalloy, is preferable, and the Ti-based alloy, the Co-based alloy, andthe Ni-based alloy, which are used for precision casting, are especiallypreferable as these alloys.

As described above, according to the casting method of the presentinvention, by using the mold 70 having the porous layer 74 on thesurface 76 of the cavity of the shell 71, wherein the porous layer 74has the three-dimensional porous structure 73, the cast article 90 whichcould not be manufactured by the casting method heretofore, having theporous layer 94 on the surface thereof can be obtained, wherein theporous layer 94 has a complicated, three-dimensional porous structure93. This cast article cannot be manufactured by the conventional method.That is, a porous body having the porous layer on the surface thereofcan be obtained, wherein the porous layer has the three-dimensionalporous structure. Further, the porous layer 94 in the cast article 90can be integrally formed with a main body, and the cast article 90 canbe easily manufactured.

Further, the cast article 90 manufactured by the casting methodaccording to the present preferred embodiment can be applied to a membernecessary for having a large surface area, such as a carrier of acatalyst, an implant member, or the like, a rotary member or a blademember for a jet engine or a gas turbine engine, or a honeycomb member,or the like. The cast article 90 can be easily manufactured for a shorttime, as compared with the conventional manufacturing method describedabove.

Particularly, when a carrier of a catalyst is cast and formed by thecasting method according to the present preferred embodiment, since thecarrier of the catalyst has a porous layer on the surface thereof, alarge amount of catalysts can be supported as compared with theconventional carriers of catalysts. Further, when an implant member iscast and formed similarly, the implant member can be strongly combinedwith biomedical tissues since it has a porous layer on the surfacethereof. Because it is generally required that the implant member hasthe porous layer on the surface thereof, and the cast article 90obtained by the casing method according to the present preferredembodiment is suitable as the implant member. Furthermore, when a rotoror a blade of a turbine; for example, a rotary member or a blade memberof a jet engine or a gas turbine engine is cast and formed similarly,since these members have a porous layer on the surface thereof, weightsof these members can be reduced, and a large amount of bubble layers canbe formed on the surface of each member. As a result, these bubblesexert a heat insulation effect, and thus the member can keep thesufficient high temperature strength even when it is a thin member, andthe weight of the member can be reduced.

Further, when casting since a core, which is not shown, is placed at anarbitrary part in the cavity 72 of the mold 70 according to the presentpreferred embodiment, which is illustrated in FIG. 7, a hollow part canbe formed at an arbitrary part of the cast article 90. As a result, theweight of the cast article 90 can be reduced.

In addition, in the present preferred embodiment, the case of formingthe wax molding body by using the metal mold is described, but it is notespecially limited to the metal mold. As a mold for forming a waxmolding body, any mold can be used if it is generally used for moldingwaxes, plastics or the like. For example, a plastic mold or a woodenmold may be used.

Then, the other preferred embodiment of the present invention isdescribed with the drawings.

A flow chart of the casting method of a cast article according to theother preferred embodiment of the present invention is shown in FIG. 10.In addition, the same codes as those of FIG. 1 are used in the sameprocesses in FIG. 10.

As illustrated in FIG. 11, the casting method according to the formerpreferred embodiment comprised the steps of forming the wax mold 21,randomly scattering many combustible powdery particles around the waxmold 21, and adhering and forming the layer 31 of the group of powderyparticle 32 around the wax mold 21.

On the other hand, the casting method according to the present preferredembodiment is characterized by a step of adhering and forming a layer ofa group of powdery particle on the inner surface of a metal mold forforming a wax mold.

Specifically, a metal mold (a female mold) having a cavity with apredetermined shape is produced at first (Process A), as shown in FIG.10. A layer of many combustible powdery particles is formed on thedesired part of the inner surface of the metal mold (Process D2). Forexample, as illustrated in FIG. 12A, when a wax material 123 is injectedinto a cavity 122 of a metal mold 121, a layer 125 comprising manypowdery or granular combustible powdery particles 124 is preformed, soas to be placed at a part on the inner surface of the metal mold 121,wherein the part is desired to have a three-dimensional porousstructure. The layer 125 is preformed using an adhesion means(adhesives, mold lubricants, vaseline, lanolin or the like). The layer125 may be formed as a plurality of layers if necessary. As the powderyparticles 124, the same particles as the powdery particles 32illustrated in FIG. 4 can be used.

Then, the wax material (wax) 123 is poured into the cavity 122, or thewax material 123 is injected into the cavity 122 by the injectionmolding method or the like (Process B). After hardening the wax material123, a wax molding body 120 is taken out from the metal mold 121(Process C). As illustrated in FIG. 12B, the wax molding body 120 has alayer 126 on the surface thereof, wherein the layer 126 has athree-dimensional porous structure, and the outer surface of the layer126 has no irregularities, that is, the height is approximately uniform,and the surface is smooth. By using this wax molding body 120, a waxmold (a male mold) 101, which is a lost pattern, can be obtained.

The desired wax mold 101 may be obtained by repeating the processes A,D2, B and C as needed to form two kinds or more of wax molding bodies,and by assembling them. The wax mold 101 comprises an ingate, a runner,and a sprue, which are used in the below-described casting although notillustrated in the drawings. Further, a plurality of wax molds 101 maybe integrated into a tree shape or a cluster shape. The wax material inthis case includes not only waxes themselves but also whole resins(plastics).

Then, the processes E and F are carried out for the wax mold 101 in thesame procedure as that of the casting method according to the formerpreferred embodiment, to thereby obtain a mold precursor 102 having avoid space in a slurry film. In this process, the powdery particles 124do not vanish but remain in the slurry film, and the shape of eachpowdery particle 124 (layer 125) is kept.

Then, the process G is carried out for the mold precursor 102 in asimilar procedure to that of the casting method according to the formerpreferred embodiment, to thereby obtain a mold 103 made of ceramicshaving a cavity inside the shell, wherein the cavity is comprised of acavity having the same shape as the wax mold 101 and a group of the finevoid space having the same shape as each powdery particle 124 (the layer125). That is, the mold 103 has a porous layer on the surface of thecavity of the shell, wherein the porous layer has a three-dimensionalporous structure having a substantially uniform depth.

Then, the processes H, I and J are carried out for the mold 103 in asimilar procedure to that of the casting method according to the formerpreferred embodiment, to thereby obtain a cast article 104. The castarticle 104 has a porous layer at least on the surface thereof, whereinthe porous layer has a three-dimensional porous structure. The castarticle 104 having the smooth outer surface of the porous layer is acomparatively flat integral body.

In the process D2, by controlling an arrangement of each powderyparticle 124 adhered on the inner surface of the metal mold 121, it ispossible to obtain the layer 125 having a porous structure whose poresare randomly arranged or a porous structure whose pores are aligned in apredetermined direction. Further, by changing the size and shape of thepowdery particles 124, the pore size and pore shape of the layer 125having the porous structure can be controlled. Furthermore, bycontrolling the thickness of the layer 125, the thickness of the porouslayer of the mold 103, that is, the thickness of the porous layer of thecast article 104 can be controlled.

Further, in the process B, when the wax material 123 is poured, thetemperature of the wax material 123 is controlled to be between thesoftening point or more and the melting point+30° C. or less. Thereby,the viscosity of the wax material 123 is controlled, and the waxmaterial 123 does not reach to the surface of the metal mold 121 passingthrough the gap between the powdery particles 124 due to the surfacetension of the wax material 123. Further, when the wax material 123 isinjected by injection molding, the injection pressure is controlled tohave a suitable value so that the wax material 123 does not reach to thesurface of the metal mold 121 passing through the gap between thepowdery particles 124.

Further, in the process C, when the wax molding body 120 is taken outfrom the metal mold 121, it can be taken out intact in most cases whenmold lubricant, vaseline, lanolin, or the like is used as the adhesionmeans. Meanwhile, when the adhesive is used as the adhesion means, apeeling liquid for the adhesive is poured into the gap between the metalmold 121 and the wax molding body 120, to thereby take out the waxmolding body 120 after the adhesive is peeled off.

Also in the casting method according to the present preferredembodiment, it is possible to obtain the similar working effect to thatof the casting method according to the former preferred embodiment.

Further, as for the casting method according to the present preferredembodiment, since the layer 126 formed on the surface of the wax mold101 is formed using the inner surface of the metal mold 121, thereproducibility of the layer 126 is favorable as compared with thecasting method according to the former preferred embodiment, where thelayer 31 is formed by randomly scattering many powdery particles 32 onthe surface of the wax mold 21.

Further, as for the cast article 90 obtained by the casting methodaccording to the former preferred embodiment, the outer surface (theoutline) of the porous layer 94 having the three-dimensional porousstructure 93 is not uniform and irregular. In this case, when an implantmember using the cast article 90 is embedded (implanted) in biomedicaltissues, the implant member may be caught by the biomedical tissues dueto the ununiform and irregular outer surface of the porous layer 94. Inorder to prevent this problem, it is necessary that the surface of theporous layer 94 of the implant member (the cast article 90) is subjectedto a machining to remove the irregularity in order to decrease thechance to be caught and to increase embeddability. As a result, althoughthe outer surface of the porous layer 94 can be made uniform, a part ofthe porous structure 93 of the porous layer 94 of the cast article 90must be scraped away. Thus, the utilization of the formed porousstructure cannot be maximized.

As for the casting method according to the present preferred embodiment,when the wax mold 101, which is the lost pattern, is manufactured, theshape of the outer surface of the layer 125 becomes substantially equalto the shape of the inner surface of the metal mold 121 by pasting thelayer 125 comprising the many powdery particles 124 on the inner surfaceof the metal mold 121 in advance. As a result, as for the wax moldingbody 120 obtained by pouring the wax material 123 into the metal mold121, the outer surface of the layer 126 formed on the surface issubstantially uniform and smooth. Thereby, also as for the cast article104, which is finally obtained by using the wax mold 101, the outersurface of the porous layer having the porous structure is substantiallyuniform and smooth. Therefore, when an implant member is manufacturedusing the cast article 104, it is not necessary to perform machineprocessing on the outer surface of the porous layer of the implantmember, and the implant member can be embedded without being caught justas it is manufactured (without processing). That is, the utilization ofthe porous structure of the porous layer of the cast article 104 can bemaximized, and the manufacturing efficiency of the porous structure isfavorable.

In the casting method according to the present preferred embodiment,described is the case where the layer 125 consisting of many powderyparticles 124 is adhered and formed on the inner surface of the metalmold 121 for forming the wax mold 101 by the adhesion means. However, itis not especially limited to this case. For example, when thecombustible powdery particles 124 constituting the layer 125, which ispreformed on the inner surface of the metal mold 121, are magneticparticles, the layer 125 can be formed on the inner surface of the metalmold 121 by only applying a magnetic field to the metal mold 121. Inthis case, the wax molding body 120 is taken out from the metal mold 121by only the steps for pouring the wax material 123, hardening it, andstopping the application of the magnetic field to the metal mold 121.Thus, the wax molding body 120 can be easily taken out.

As described above, the present invention is not limited to theabove-described preferred embodiments, and needless to say, variousembodiments can be considered in addition to the above preferredembodiments.

Hereinafter, the present invention is described on the basis ofexamples, but it is not limited to these examples.

EXAMPLE 1

Wax was poured at 80° C. into a metal mold having a cavity with apredetermined shape. After hardening the wax, a pattern (a wax moldingbody) was taken out from the metal mold. The wax molding body thusobtained was shaped to have a tree shape, to thereby manufacture awax-mold.

A spray paste was sprayed onto a part of the wax mold, wherein the partwas desired to be porous, and many wood pieces having sizes ofapproximately 0.5 to 1.0 mm were scattered and adhered on the partsprayed with the spray paste. This work was repeated as appropriate, tothereby form a porous layer having a porous structure, wherein theporous layer had many wood pieces piled up to have a plurality oflayers.

Then, slurry for precision casting was coated on the wax mold having theporous layer, and it was dried for 3 hours or more, to thereby form aslurry film. This work was repeated 9 times in total.

Then, the wax mold was heated and pressurized at 140 to 150° C. and 5 to6 atmospheres for 7 minutes to dewax the wax mold, to thereby obtain awax precursor (a wax preformed body). Then, the wax precursor wassubjected to a firing treatment at 1,100° C. for 2 hours, to therebymanufacture a mold consisting of a shell obtained by firing andhardening the slurry.

Then, the mold was preheated at 900° C., and a molten Co-basedsuperalloy was poured into the cavity of the mold at a molten metaltemperature of 1,500° C. to cast it. Then, the molten metal was cooled,to thereby manufacture a cast body in the mold.

Then, the mold was subjected to a sandblast treatment to remove theshell, to thereby manufacture a cast article.

As the cross-sectional observation view of the cast article isillustrated in FIG. 13, a cast article 130 had integrally a porous layer133 at least on the surface of a main body 131, wherein the porous layer133 had a three-dimensional porous structure 132. As for the porouslayer 133, the height of the outer surface was not uniform and the outersurface was irregular.

EXAMPLE 2

Vaseline was coated on the inner surface of a metal mold having a cavitywith a predetermined shape. Then, a spray paste was sprayed onto a partof the inner surface of the metal mold, wherein the part was desired tobe porous, and many wood pieces having sizes of approximately 0.5 to 1.0mm were scattered and adhered on the part sprayed with the spray paste.This work was repeated as appropriate, to thereby form a porous layerhaving a porous structure, wherein the porous layer had many wood piecespiled up to have a plurality of layers.

Then, a wax was poured into the metal mold at 80° C. After hardening thewax, a pattern (a wax molding body) was taken out from the metal mold. Awax molding body thus obtained was shaped to have a tree shape tothereby manufacture a wax mold.

A cast article was manufactured in a manner similar to Example 1 exceptfor the use of this wax mold.

As the cross-sectional observation view of the cast article isillustrated in FIG. 14, a cast article 140 had integrally a porous layer143 at least on the surface of a main body 141, wherein the porous layer143 had a three-dimensional porous structure 142. As for the porouslayer 143, the height of the outer surface was uniform and the outersurface was not irregular.

EXAMPLE 3

As for the cast article 130 obtained in Example 1 and the cast article140 obtained in Example 2, porosities of the porous layers 133 and 143were compared.

As a result, the cast article 130 in Example 1 has 30% higher porosityin the porous layer 133 than that in the porous layer 143 of the castarticle 140 in Example 2. Specifically, in the porous layer 133 of thecast article 130 in Example 1, the pore rate in a certain cross sectionwas about 50%. On the other hand, in the porous layer 143 of the castarticle 140 in Example 2, the pore rate in a certain cross section wasabout 35%. Due to an irregular height of the outer surface of the porouslayer 133, the cast article 130 was considered to have higher porositythan that of the cast article 140 having a uniform height of the outersurface of the porous layer 143.

Further, in the cast articles 130 and 140 in Example 1 and Example 2,the depths of the porous layer from the uppermost surface to the deepestpart were 2.08 mm and 1.96 mm, respectively, and these were consideredto be substantially equal. That is, with respect to the depth of theporous layer, there was substantially no difference in both articles.

1. A method for manufacturing a mold having a porous layer having athree-dimensional porous structure on a surface of a cavity of a shell,the method comprising, a step D for forming a layer of combustiblepowdery particles around a wax mold, which is a lost pattern, a step Efor coating a film of a ceramic precursor slurry around the wax moldhaving the layer of the powdery particles formed thereon, a step F forsubjecting the wax mold coated with the slurry film to a heat treatment,to thereby dewax the wax mold, and a step G for firing the slurry film,to thereby burn and vanish the powdery particles in the slurry film andform a shell.
 2. A method for manufacturing a mold having a porous layerhaving a three-dimensional porous structure on a surface of a cavity ofa shell, the method comprising, a step D2 for forming a layer ofcombustible powdery particles on the inner surface of a female mold forforming a wax mold, which is a lost pattern, a step B for pouring a waxmaterial into the female mold, to thereby form the wax mold having thelayer of the powdery particles around thereof, a step E for coating afilm of a ceramic precursor slurry around the wax mold, a step F forsubjecting the wax mold coated with the slurry film to a heat treatment,to thereby dewax the wax mold, and a step G for firing the slurry film,to thereby burn and vanish the powdery particles in the slurry film andform a shell.
 3. The method for manufacturing the mold according toclaim 1 or 2, wherein the powdery particles are burned and vanished nearthe firing temperature of the slurry film in said step G.
 4. The methodfor manufacturing the mold according to claim 3, wherein the powderyparticles are burned and vanished at a temperature lower than the firingtemperature of the slurry film by 90° C. or more in said step G.
 5. Amold manufactured by the method for manufacturing the mold according toclaims 1, 3 and 4, wherein said mold has the porous layer on the surfaceof the cavity of the shell, and said porous layer has thethree-dimensional porous structure.
 6. A mold manufactured by the methodfor manufacturing the mold according to claims 2, 3 and 4, wherein saidmold has the porous layer on the surface of the cavity of the shell, andsaid porous layer has the three-dimensional porous structure.
 7. Acasting method for manufacturing a cast article using the mold obtainedby the method for manufacturing the mold according to claims 1, 3 and 4,the method comprising, a step H for pouring a molten metal into thecavity of the mold, a step I for cooling the molten metal, and a step Jfor removing the shell of the mold.
 8. A casting method formanufacturing a cast article using the mold obtained by the method formanufacturing the mold according to claims 2, 3 and 4, the methodcomprising, a step H for pouring a molten metal into the cavity of themold, a step I for cooling the molten metal, and a step J for removingthe shell of the mold.
 9. A casting method of the cast article accordingto claim 7 or 8, wherein the shell is removed by a blast cleaning methodin said step J.
 10. A cast article manufactured by the casting methodaccording to claim 7 or 9, wherein said article has a porous layer atleast on the surface thereof, and said porous layer has athree-dimensional porous structure.
 11. A cast article manufactured bythe casting method according to claim 8 or 9, wherein said article has aporous layer at least on the surface thereof, and said porous layer hasa three-dimensional porous structure.
 12. An implant member manufacturedby the casting method according to claim 7 or 9, wherein said member hasa porous layer at least on the surface thereof, and said porous layerhas a three-dimensional porous structure.
 13. An implant membermanufactured by the casting method according to claim 8 or 9, whereinsaid member has a porous layer at least on the surface thereof, and saidporous layer has a three-dimensional porous structure.
 14. A catalystcarrier manufactured by the casting method according to claim 7 or 9,wherein said carrier has a porous layer at least on the surface thereof,and said porous layer has a three-dimensional porous structure.
 15. Acatalyst carrier manufactured by the casting method according to claim 8or 9, wherein said carrier has a porous layer at least on the surfacethereof, and said porous layer has a three-dimensional porous structure.16. A turbine rotor manufactured by the casting method according toclaim 7 or 9, wherein said rotor has a porous layer at least on thesurface thereof, and said porous layer has a three-dimensional porousstructure.
 17. A turbine rotor manufactured by the casting methodaccording to claim 8 or 9, wherein said rotor has a porous layer atleast on the surface thereof, and said porous layer has athree-dimensional porous structure.
 18. A turbine blade manufactured bythe casting method according to claim 7 or 9, wherein said blade has aporous layer at least on the surface thereof, and said porous layer hasa three-dimensional porous structure.
 19. A turbine blade manufacturedby the casting method according to claim 8 or 9, wherein said blade hasa porous layer at least on the surface thereof, and said porous layerhas a three-dimensional porous structure.